2005 2006 2007 Kawasaki KX125 KX250 models Service Repair Manual

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Mots clés: 2005 2006 2007 Kawasaki KX Series KX125 KX250 Motorcycle Motorcycles

Variantes de produits

Description

This manual covers the KX125 and KX250 models produced for the 2005, 2006, and 2007 model years. These two-stroke, liquid-cooled off-road motorcycles are renowned for their potent engines and competitive chassis, making them a popular choice in the motocross community. The KX line has a rich heritage, with these particular years representing significant refinements in performance and handling, often featuring advanced suspension components like Kayaba SSS forks. They offer a direct and engaging riding experience, favored by riders seeking peak performance on the track. This comprehensive Service Repair Manual provides essential information for the maintenance, repair, and diagnostics of your KX125 or KX250. It covers all major systems, including the engine, fuel system, cooling system, transmission, brakes, suspension, steering, and electrical components. Detailed procedures for routine maintenance, component replacement, and troubleshooting are included, supported by numerous diagrams and illustrations. This manual is designed to empower owners and technicians to keep these high-performance machines in optimal condition.

🏷️ Basic Information

Identification

Make:

Kawasaki

Model:

KX250

Year:

2005, 2006, 2007

Codes

Manual Part Number:

99924-1298-06

👋 Introduction

Market Position

Target Audience:

DIY mechanics, home mechanics, owners of Kawasaki KX125 and KX250 models from 2005-2007 seeking to perform maintenance, repairs, and diagnostics to save on dealer labor costs.

Competitive Analysis

Value Proposition:

Provides comprehensive, dealership-level repair information at a fraction of the cost of dealer labor or authorized service manuals. Instant download eliminates shipping delays.

Key Features

Manual Benefit:

Enables owners to perform most maintenance and repairs themselves, fostering a deeper understanding of their motorcycle and extending its lifespan.

📋 Manual Details

Coverage Areas

General Information:

Included

Periodic Maintenance:

Included

Fuel System:

Included

Cooling System:

Included

Engine Top End:

Included

Engine Lubrication System:

Included

Engine Removal Installation:

Included

Crankshaft Crankcase:

Included

Transmission:

Included

Wheels Tires:

Included

Final Drive:

Included

Brakes:

Included

Suspension:

Included

Steering:

Included

Frame:

Included

Electrical System:

Included

Diagnostics:

Included

Page Count

Total Pages:

Manual Type

Type:

Service Repair Manual

Language

Language:

English

Format

File Format:

Compatibility:

All Versions of Windows & Mac

Requirements:

Adobe PDF Reader

📖 Manual Coverage

Systems Covered

Engine Systems:

Top End (cylinder, piston, rings, head), Lubrication System (oil pump, passages, oil cooler), Crankshaft & Crankcase, Transmission (gearbox, clutch, shifting mechanism), Cooling System (radiator, coolant passages, water pump)

Chassis Systems:

Wheels & Tires (rims, spokes, bearings, tire pressure, mounting), Final Drive (chain, sprockets, adjustment), Brakes (front and rear calipers, master cylinders, brake lines, pads, fluid), Suspension (forks, shock absorber, linkages, springs, damping adjustment), Steering (handlebars, steering stem, bearings), Frame (chassis integrity, mounting points)

Electrical Systems:

Ignition System, Lighting System, Wiring Harness, CDI Unit, Spark Plug, Troubleshooting Electrical Faults

Procedures Included

Maintenance Procedures:

Oil changes, chain lubrication and adjustment, air filter cleaning/replacement, spark plug inspection and replacement, coolant checks and changes, brake fluid replacement, wheel bearing service, steering bearing service, general cleaning and inspection

Repair Procedures:

Engine top-end rebuilds (piston, cylinder, head), crankshaft and bearing replacement, transmission overhaul, clutch service and replacement, carburetor tuning and rebuild, radiator repair, brake caliper and master cylinder rebuild, suspension fork seal replacement, steering stem bearing replacement, electrical component testing and replacement

Troubleshooting Diagnostics:

Step-by-step diagnostic guides for common running issues, performance problems, electrical faults, and component failures. Includes symptom-based troubleshooting trees.

Technical Depth

Depth Level:

Comprehensive: Covers everything from routine maintenance and adjustments to complete engine and transmission rebuilds, and detailed electrical system diagnostics.

Illustrations Diagrams:

Detailed diagrams, illustrations, photos, and exploded views for all major components and systems.

Features:

Clickable menu, keyword searchable text, printable pages, bookmark functionality, zoom in/out capability.

📊 Manual Specifications

File Format

PDF Quality:

High Resolution

Searchability:

Keyword Searchable

Print Quality

Printability:

Fully Printable (individual pages, chapters, or entire manual)

Binding Type

Suggested Binding:

3-ring binder (for ease of page replacement)

Paper Type

Recommendation:

Print on demand for garage use, easily replaceable if soiled.

⚙️ Engine Specifications

Primary Engine

Kx125 Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Kx125 Displacement:

124 cm³ (7.57 cu in)

Kx125 Bore X Stroke:

54.0 x 54.5 mm (2.13 x 2.15 in)

Kx125 Compression Ratio:

9.5:1 (typical, may vary by region/tune)

Kx250 Engine Type:

Liquid-cooled, 2-stroke, single-cylinder

Kx250 Displacement:

249 cm³ (15.2 cu in)

Kx250 Bore X Stroke:

66.4 x 72.0 mm (2.61 x 2.83 in)

Kx250 Compression Ratio:

9.3:1 (typical, may vary by region/tune)

Performance

Kx125 Horsepower Estimate:

Approx. 35-40 HP (Varies with tuning and exhaust)

Kx250 Horsepower Estimate:

Approx. 45-50 HP (Varies with tuning and exhaust)

Fuel System

Carburetor Type:

Keihin PWK (e.g., PWK38 for KX250, PWK36 for KX125)

Fuel Type:

Unleaded gasoline with 2-stroke oil pre-mix (specified ratio in manual)

Fuel Tank Capacity:

Approx. 8.0 Liters (2.1 US gallons)

🔧 Transmission

Standard

Gearbox:

5-speed, constant mesh, sequential return

Features

Clutch:

Wet, multi-disc, cable-actuated

Transmission Oil Type:

Kawasaki Motorcycle Gear Oil 10W-40 or equivalent API GL-4

Transmission Oil Capacity:

Approx. 0.6 - 0.7 Liters (Varies slightly by model)

📐 Dimensions

Exterior

Wheelbase:

Approx. 1450-1470 mm (57.1-57.9 in) (Varies by model and year)

Ground Clearance:

Approx. 330-355 mm (13.0-14.0 in) (Varies by model and year)

Weights

Dry Weight:

Approx. 91-97 kg (200-214 lbs) (Varies by model and year)

Wet Weight:

Approx. 98-105 kg (216-231 lbs) (Varies by model and year, includes all fluids)

🛡️ Safety Features

Ratings

Safety Focus:

This is a motocross/off-road competition vehicle, not equipped with typical road safety features like ABS, airbags, or advanced driver-assistance systems. Safety is primarily rider-dependent and focused on vehicle control.

Active Features

Braking System:

Hydraulic disc brakes front and rear for strong stopping power.

Passive Features

Chassis Design:

Strong perimeter frame designed for rigidity and rider feedback.

💡 Technology Features

Infotainment

Features:

Not applicable to this type of off-road performance motorcycle.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Every 5-10 hours of riding or annually, depending on riding conditions (refer to manual for specific recommendations).

Air Filter Cleaning:

After every few rides or more frequently in dusty conditions.

Chain Lubrication Adjustment:

Before every ride or as needed.

Spark Plug Inspection:

Every 10-20 hours of riding.

Fluid Specifications

Engine Oil Premix Ratio:

Typically 20:1 or 32:1 with high-quality 2-stroke racing oil (specified in manual, e.g., Klotz, Maxima, Motul).

Coolant Type:

Ethylene glycol based coolant with distilled water (50/50 mix) or a specific motorcycle coolant.

Brake Fluid Type:

DOT 4 brake fluid.

Known Issues

Common Wear Items:

Piston rings and piston wear, clutch plates, spark plugs, wheel bearings, steering bearings, chain and sprockets, brake pads.

Performance Tuning Considerations:

Carburetor jetting adjustments are critical for optimal performance and preventing engine damage, especially with changes in altitude or temperature. Exhaust pipe and silencer condition also impact performance.

📚 Vehicle History

Brand Heritage

Kawasaki Offroad Legacy:

Kawasaki has a long and storied history in motocross, with the KX line being a dominant force for decades, known for its potent engines and competitive chassis.

Model Evolution

Kx125 Kx250 2000S:

The 2005-2007 models represent a refinement of Kawasaki's successful 2-stroke motocross platform. These years featured significant updates aimed at improving performance, handling, and suspension, including Kayaba (KYB) SSS (Speed Sensitive System) forks in later iterations, known for their plushness and adjustability.

Production

Manufacturing Location:

Japan (typically)

🏆 Awards & Recognition

Recognitions

Model Reputation:

The KX125 and KX250 models of this era were highly regarded in the motocross community for their powerful engines and capable chassis, often favored by riders for their performance potential and direct feedback.